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EfficientProducts.org: Researching & Reporting on the Energy Efficiency of Consumer Products
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Battery Charger Systems

Update: The Energy Commission has released
a call for test data using revision (2.2) to the Final California Battery Charger Systems Test Procedure . A test data template is required.

In just the last two decades, product convenience has improved by leaps and bounds with the growth of an entirely new family of products that incorporate batteries instead of relying always on the wall plug to supply electricity. For larger products, these batteries can even replace the combustion engine. The once common disclaimer “Batteries not included” is slowly becoming a thing of the past as numerous manufacturers incorporate rechargeable batteries and custom chargers into their products so that consumers need only plug a device into the wall to “refill the tank.”

Laptops, cordless tools, electric golf carts, cordless phones, electric toothbrushes, portable music players, cell phones – all are dependent to some extent on rechargeable batteries. These products offer substantial economic and environmental advantages over products powered by throwaway batteries and are more convenient than corded products. Certain products, like cordless tools, might not even be feasible without custom rechargeable batteries. However, every rechargeable battery-powered product wastes some amount of energy in the process of charging a battery – energy that cannot be used by the product, but which still appears on the user’s electric bill and results in increased air pollution from power plants. Using more efficient rechargeable battery-powered products saves energy and ensures that these costs stay to a minimum.

What do we mean when we say "battery charger systems"?

Cell phone charger diagram.It’s quite easy to name a handful of portable products that contain rechargeable batteries, but just what is a battery charger system and how does it work? A battery charger is a set of electronic devices used to convert high voltage AC electricity from a wall outlet into lower voltage DC electricity that is carefully supplied to a rechargeable battery. There, the electricity is further converted into chemical energy and stored. A battery charger may be a stand-alone device, such as chargers produced by battery manufacturers to recharge common battery types like AA, AAA, C, or D cells. On the other hand, battery chargers may be an internal subsystem of a larger product such as a cell phone. See the illustration for an example of how a battery charger might be integrated into a cell phone or similar product and how power from the wall outlet flows through the system. The red box shows the components – internal and external to the phone – that are considered part of the battery charger system.

Battery charger systems include the following three components:

  • A power supply that converts high voltage AC electricity into lower voltage DC electricity
  • Battery charger circuitry that controls the flow of electric current into a battery
  • A battery that stores the electric current provided by the battery charger circuitry in the form of chemical energy

Battery and charger systems are used in a wide range of products and differ mainly in size (the amount of power that is meant to flow through the charger when it is recharging batteries) and battery chemistry. Four battery chemistries currently dominate the market, including: nickel-cadmium (NiCd), nickel-metal hydride (NiMH), lithium-ion (Li-Ion), and sealed lead acid (SLA).

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How many battery chargers are in use
and how much energy do they use?
Today, over 1 billion products that contain rechargeable batteries and battery chargers are currently in use in America’s homes, offices, retail spaces, and warehouses [1]. This is one of the most diverse group of products currently covered on EfficientProducts.org, spanning everything from low-power cordless or cellular telephones all the way up to high-power battery-operated forklifts used in industrial facilities or even electric vehicles.

Current market research conducted by Ecos suggests that battery powered products consume over 30 billion kWh of electricity annually, enough to power the state of Connecticut. Anywhere from 40% to as much as 80% of that energy could be saved cost effectively through relatively simple design improvements.

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How can I find today's most efficient battery chargers?
Consumers wishing to identify the most efficient consumer battery charging products can currently look for ENERGY STAR labeled products. ENERGY STAR, unfortunately, only covers a subset of battery charging products, so EfficientProducts.org recommends some of the following additional guidelines when shopping for products that fall outside the scope of ENERGY STAR's battery charger specification:

  • For products that are bundled with external power supplies, check the product’s packaging to see if its external power supply meets the criteria of the ENERGY STAR program. This will be signified either with an ENERGY STAR label or using a small roman numeral (roman numerals IV or higher indicate that the power supply complies with ENERGY STAR's "tier 1" external power supply specification). Although this does not address the efficiency of the entire battery charging system, it does ensure that one component of that system is efficient compared to others on the market. NOTE: Some battery charger products (power tools, kitchen tools, lawn care devices, personal hygiene items, and other battery chargers that produce heat, light, or motion) are specifically exempt from this label.
  • If you cannot find a suitable product bearing the ENERGY STAR external power supply label, look for battery charging products that utilize switch-mode power supplies like the one shown below. These power supplies are flatter, more lightweight, more compact, and more efficient than traditional linear power supplies.

  • Try to purchase battery-powered products with indicator lights that indicate when the battery is fully charged. Then, remove the battery from the charger and unplug it after the charge is complete.

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What is the definition of efficiency?
The definition of whole-product battery charger efficiency is still a topic of debate in the energy efficiency community, but we do know a lot about how battery chargers operate and where they can waste energy.

The operation of battery chargers can be broken down into three distinct modes. The first is charge mode. This is the time when the battery charger is actively charging a connected battery. So-called “rapid” battery chargers that force high amounts of charge into batteries in a short period of time can consume a lot of energy in this mode.

Once the battery is fully charged, the battery charger enters the second mode of operation: battery maintenance mode. Battery chargers usually consume less power in this mode than when they are actually charging a battery, but some inexpensive consumer appliances continue to draw a high level of power in battery maintenance mode, even after the battery is completely charged.

The third and final mode of operation is called standby mode. This is the time when the battery charger is connected to a wall outlet but the charger is not connected to a battery or a battery-containing product. This situation might occur, for example, if someone leaves their cell phone AC adapter plugged in by their nightstand so that they can charge their cell phone when they go to bed. The AC adapter will continue to draw power from the wall outlet during the day even when it isn’t connected to the cell phone.

Different organizations have developed slightly different methods for defining and measuring efficiency in battery chargers, particularly when it comes to charge mode. A test procedure that focuses on power tools, lawn care products, hygiene products, and kitchen tools is available from the EPA’s ENERGY STAR program. Ecos Consulting and EPRI have developed a separate and more comprehensive test procedure for all types of residential and commercial battery charger systems under work funded by the California Energy Commission’s (CEC) Public Interest Energy Research (PIER) program and Pacific Gas and Electric Company (PG&E).

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  1. According to 2008 market estimates made by Ecos Consulting.

What's new?

NEW! California Energy Commission Call for Data

NEW! Battery Charger Data Collection Template

NEW! Revision 2.2 Final California Battery Charger Systems Test Procedure


Events

California Energy Commissions 2008 Title 20 Rulemaking

May 30, 2007 Battery Charger Systems Test Procedure Workshop

November 2005 California Battery Charger Systems Test Procedure Workshop


Research

Battery Charger Technical Primer
A technical design primer jointly authored by Ecos Consulting and EPRI, highlighting efficient design strategies for consumer battery charger systems.

Energy Commission Battery Charger Presentation 2006
A presentation given by Ecos Consulting summarizing current California Energy Commission research on battery charger energy efficiency, given at the 2006 "Advancements in Battery Technology and Power Management Conference" in Chicago.

Energy Commission Battery Charger Presentation
A presentation given by Ecos Consulting summarizing current California Energy Commission research on battery charger energy efficiency, given at the 2005 "Advancements in Battery Technology and Power Management Conference" in Vancouver, BC.

NRDC Battery Charger Report
Scoping research on the opportunity for energy savings through battery charger efficiency.

NRDC Battery Charger Efficiency PPT
A presentation given by Ecos Consulting on battery charger efficiency basics.

NRDC Laptop Efficiency Summary
Report on energy-saving features and opportunities in laptop computers, a battery-powered product.


Test Methods

Revision 1.2 Final California Battery Charger Test Procedure
An updated version of the Fall 2007 California Battery Charger Test Procedure. This version addresses stakeholder comments from April 2008 California Energy Commission stakeholder workshops.

Revision 1.1 Final California Battery Charger Test Procedure
An updated version of the Fall 2007 California Battery Charger Test Procedure. This version includes updates related to the charging and discharging of batteries of unknown rated capacity.

Final California Battery Charger Test Procedure
This document is the final version of a comprehensive battery charger system efficiency test procedure developed by Ecos Consulting and EPRI.

Working Draft California Battery Charger Test Procedure

Draft 2 California Battery Charger Test Procedure
This document is the second draft of a comprehensive battery charger test procedure being developed by Ecos Consulting and EPRI Solutions. Please send any comments to Suzanne Foster Porter at Ecos Consulting by May 15, 2006.

EPA ENERGY STAR Battery Charger Test Method
A test method currently being used to by the EPA ENERGY STAR program to evaluate products for its battery charger specification.


Programs and Policies

U.S. Department of Energy (DOE) Federal Battery Charger Standards Web Page

ENERGY STAR battery charger specification

ENERGY STAR external power supply specification


Other Useful Info

EPA Battery Alert

Information on EPA Battery Act

Rechargeable Battery Recycling Corporation

Worldwide battery laws

Electric and Hybrid Vehicle Links

How Stuff Works - Batteries


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© 2008 Ecos Consulting
Send questions or comments to efficientproducts@ecosconsulting.com.